Integration of smart materials into high-volume manufacturing methods

Emanuele Bianchini

doi:10.1117/12.659167

30 March 2006 Integration of smart materials into high-volume manufacturing methods

Emanuele Bianchini

Proceedings Volume 6171, Smart Structures and Materials 2006: Industrial and Commercial Applications of Smart Structures Technologies; 61710A (2006) https://doi.org/10.1117/12.659167
Event: SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring, 2006, San Diego, California, United States

Abstract

The integration of smart materials such as piezoelectric devices and shape memory alloys into structures has been typically limited to a bonding process that occurs as a secondary operation. Such an operation is not only costly for high volume applications but also has the potential of degrading the performance of the actuator or sensor due to the bonding agent selected. The work presented here explores the integration of piezoelectric materials using a high volume injection molding process. The process used is typical for large automotive components such as bumpers, instrument panels and other body panels. Different materials were evaluated, including plastics and both bare and packaged smart materials. Temperature and flow rate were also changed to investigate the effects on the durability of the materials. Both electrical and mechanical properties were tested with the key parameters including, void content, shifting from initial position, strain transfer and peal strength. It was found that good integration of piezoelectric materials could be achieved and electro-mechanical properties were improved as compared to a secondary bonding operation. Integration of screen-printed electrical circuits for electrical connectivity for piezoelectric materials will be evaluated in future research. In conclusion, a step forward was made in developing a multifunctional material based upon smart materials and conventional high volume manufacturing processes.

Citation Download Citation

Emanuele Bianchini "Integration of smart materials into high-volume manufacturing methods", Proc. SPIE 6171, Smart Structures and Materials 2006: Industrial and Commercial Applications of Smart Structures Technologies, 61710A (30 March 2006); https://doi.org/10.1117/12.659167

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KEYWORDS

Smart materials

Manufacturing

High volume manufacturing

Capacitance

Device simulation

Overlay metrology

Sensors

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